Back Window Glass: Service and Repair
REAR WINDOW GLASSSpecial Tool(s):
SPECIAL TOOL(S)
REMOVAL
WARNING: To prevent glass splinters from entering the eyes or cutting the hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle.
CAUTION: Care must be taken to avoid scratching the pinch weld.
1. Remove the interior trim panels surrounding the rear window glass.
2. Lower the rear portion of the headliner.
3. Remove the rear window glass.
Item 1: Rear Window Glass Removal Note
1. Disconnect the three rear window glass electrical connectors.
- Two rear defrost electrical connectors.
- FM antenna electrical connector.
2. Lower the rear portion of the headliner.
3. Using a soft brush or vacuum, remove the dirt and foreign material from the pinch weld.
4. NOTE: Lubricate the existing urethane adhesive with water to aid the special tool while cutting.
Using the special tool, starting at the top center of the rear window glass, cut the adhesive away from the glass and work down the sides.
5. Using the special tool, distance the rear window glass from the body.
6. Using the special tool, cut the remaining urethane adhesive and remove the rear window glass.
7. Using a soft brush or vacuum, remove the dirt and foreign material from the pinch weld.
INSTALLATION
1. To install, reverse the removal procedure.
Item 1: Rear Window Glass Installation Note
CAUTION: After installing the new urethane-installed rear window glass, the vehicle should not be driven until the urethane adhesive has cured. The curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. (Refer to the Essex drive away chart for the cure times as the temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive bond.
1. Dry fit the rear window glass to the existing urethane bed on the body pinch weld. Align the rear window glass in the opening for a uniform fit.
2. Use tape or non-permanent marking pencil to make alignment marks on the rear window glass (preferably at the setting blocks), and the body to aid in the installation alignment of the rear window glass.
3. After alignment, remove the rear window glass and molding assemblies from the vehicle and place on a stable work surface.
4. Trim the remaining urethane adhesive on the pinch weld using only the full-cut method. In this method, most of the existing urethane adhesive is removed leaving a level bead around the entire pinch weld.
5. WARNING: All rust found on the pinch weld must be removed and the pinch weld restored to OEM specifications. If surface rust is found, remove completely down to clean, bare metal. Prime pinch weld metal with an OEM recommended curing automotive paint primer and allow to cure correctly. If rust has penetrated through the pinch weld metal, repair the pinch weld sheet metal at a body shop before proceeding.
Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that may cause glass breakage. Clean or repair surface as necessary.
6. Use a Wool applicator to apply urethane metal primer to any exposed metal on the pinch weld. Allow six to ten minutes to dry.
7. If reinstalling the original rear window glass, remove any excess urethane adhesive.
8. Clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean.
9. CAUTION: Wipe off the urethane glass prep immediately after each application because it flash dries. Apply deliberate strokes, making sure not to overlap the applied area.
If installing a new rear window glass, apply urethane glass prep twice around the glass surface to be prepped.
10. If installing a new rear window glass, apply urethane glass primer to the same area that was prepped in the previous step. Allow five minutes to dry.
11. Cut the urethane adhesive applicator tip to specification.
12. CAUTION: If the vehicle is to be driven within 24 hours of urethane adhesive application, urethane adhesive must be used due to its one-hour cure time.
Apply a bead of urethane adhesive to the pinch weld.
13. CAUTION: Open the windows to prevent the rear window glass from being pushed out by air pressure if a door is closed.
Install the rear window glass on the pinch weld. Align the rear window glass to the body using the alignment marks while pushing downward to set the stops.
14. Inspect the rear window glass for air or water leaks and add urethane adhesive where needed.
15. Connect the three rear window glass electrical connectors.
- Two rear defrost electrical connectors.
- FM antenna electrical connector.